Roller Burnishing Process Research Articles

RETRACTED ARTICLE: Effects of roller burnishing process parameters on surface roughness of A356/5%SiC composite using response surface methodology

In this study, a simple roller burnishing tool was made to operate burnishing processes on A356/5%SiC metal matrix composite fabricated by electromagnetic stir casting under different parameters. The effects of burnishing speed, burnishing force and number of burnishing passes on the surface roughness and tribological properties were measured. Scanning electron microscopy (SEM) graphs of the machined surface with PCD (insert-10) tool and roller burnished surface with tungsten carbide (WC) roller were taken into consideration to observe the surface finish of metal matrix composites. The mechanical properties (tensile strength, hardness, ductility) of A356/5%SiC metal matrix composites were studied for both unburnished samples and burnished samples. The results revealed that the roller burnished samples of A356/5%SiC led to the improvement in tensile strength, hardness and ductility. In order to find out the effects of roller burnishing process parameters on the surface roughness of A356/5%SiC metal matrix composite, response surface methodology (RSM) (Box–Behnken design) was used and a prediction model was developed relevant to average surface roughness using experimental data. In the range of process parameters, the result shows that roller burnishing speed increases, and surface roughness decreases, but on the other hand roller burnishing force and number of passes increase, and surface roughness increases. Optimum values of burnishing speed (1.5 m/s), burnishing force (50 N) and number of passes (2) during roller burnishing of A356/5%SiC metal matrix composite to minimize the surface roughness (predicted 1.232 µm) have been found out. There was only 5.03% error in the experimental and modeled results of surface roughness.

Possibility of Steering of Product Surface Layers Properties in Burnishing Rolling Process

In this study the process of burnishing rolling is considered as a geometrical and physical boundary and initial value problem, with unknown boundary conditions in the contact area. 3D dynamic explicit method for burnishing rolling process with taking into account surface after turning (as previous treatment) under ANSYS/LS-DYNA environment was established. The analysis covered surfaces characterized by vertical angles of the asperities in range: 60°÷150°. The simulation results (i.e. surface deformation, states of strain and stresses, depth of stress deposition) were evaluated. The influence of vertical angle of the asperities after turning process on the states of stress and strain and the depth of its deposition are presented.

An Investigation for Surface Integrity of Al<sub>2</sub>O<sub>3</sub>/A356 Composites Using Roller Burnishing Process on a Milling Machine

Roller burnishing process was applied to Al2O3/A356 composite specimens. The process was carried out on vertical milling machine. Effects of the burnishing process with varying process parameters on the characteristics of the machined surface and sub-surfaces were investigated. Residual stress distribution at different depths beneath the burnished surfaces, microhardness distribution, surface roughness were used as criteria to obtain the optimum burnishing conditions that give burnished surfaces with high integrity for the Al2O3/A356 composite. Results showed an improvement in surface characteristics of Al2O3/A356 composites using burnishing process. The better surface roughness was obtained with double passes burnishing, depth of penetration of 0.12 mm, and burnishing speed of 72 mm/min. Increase of number of burnishing passes increases the value of residual compressive stress and the microhardness at the burnished surface and subsurface. The microhardness slightly decreased with the increase of burnishing speed.

Effect of roller burnishing on pure aluminum alloyed by copper

PurposeThe purpose of this paper is to review, analyze and present the effects of the roller burnishing process on pure aluminum alloyed by pure copper at 3%, 6% and 9% percentages. Roller burnishing is one of the effective finishing treatment methods in terms of stabilization of surface layers properties along the depth, Roller burnishing is one of the effective methods used to improve the surface layer properties such as microhardness and average surface roughness.Design/methodology/approachThree different Al‐Cu alloys of 3%, 6% and 9% copper additions were prepared and microstructure, micro hardness and mechanical properties investigated. Then the roller burnishing mechanism was applied on Al‐Cu alloys on cylindrical work pieces, different conditions were used, and the results were obtained and discussed.FindingsThe best enhancement in hardness was 46.4% which was achieved at 9% Cu addition, whereas the best enhancement in the flow stress was 101.8% which was achieved at 9% Cu addition. Applying burnishing force 100 and 150 N resulted in an enhancement in the micro hardness of 80% and 102.8%, respectively, in the Al‐Cu% alloy, where the maximum enhancement on the surface roughness was 61% that resulted in pure Al when applying 150 N burnishing forces. Finally it was found that pure aluminum has the highest wear resistance.Originality/valueThis is new work on Al‐Cu alloys, thus the results after implementation of roller burnishing process are of great value and add an extra enhancement in the surface quality.

Manufacturing of Tribologically Optimized Surfaces for Powertrain Applications

Among the major interests in powertrain development are the reduction of frictional losses and service life extension from improved wear resistance. Surface finishing and deterministic microstructuring have been shown to be effective methods in improving the tribological properties of sliding contacts such as bearings and cylinder liners. This is due to their acting as micro pressure-chambers and as wear debris traps. In this work, tribometric ring-on-disc tests were performed in order to evaluate the influence of surface structure − namely, the microstructure geometry and layout − on the frictional behavior of lubricated surfaces. The material combination bronze against steel as typically used in powertrain applications was investigated. The surface structures where machined using electrochemical machining by closed electrolytic free jet (Jet-ECM). It was determined that microstructuring reduced the friction coefficient by up to 45 % in the hydrodynamic regime under loads and speeds found in automotive components. The friction measurements showed that microstructures with low aspect ratios result in the least friction. In addition to the tribological investigations, the process capabilities and implementability in serial production of two surface microstructure fabrication processes: Jet-ECM and a newly developed, hybrid roller micro-embossing and burnishing process were evaluated and contrasted. It was shown that both fabrication methods can attain high structure quality.

Magnetic Assisted Roller Burnishing and Deburring of Flat Metal Surfaces

Basically, the Magnetic Assisted (MA) processes of the surface finishing can be divided into two groups: processes based on abrasion and plastic deformation. In this paper the authors present the results of experimental and developing work regarding the Magnetic Assisted Roller Burnishing (MARB) process that operates by plastic deformation and the strain hardening effect. Using Finite Element Method (FEM) modelling software system was prepared to demonstrate the experimental results.

101 ナノサイズ硫化物含有銅合金基焼結体のトライボロジー特性に及ぼす加工履歴の影響

The present study describes applicability of local surface deformation process consisted from burnishing and shot preening for surface finish on tribological properties of copper based alloy containing sulfide fine particles sintered on a steel plate. The shot peening was carried out with a developed apparatus possible to eject fine particle with a low flow rate. A roller burnishing process installed to a conventional lathe was applied to truncate after the peening process. A ring on disc type testing apparatus was used to evaluate tribological properties with a hardened carbon steel ring as a mating specimen with a mirror finished surface in lubricated condition. Results showed that the application of the truncation was effective to reduce the friction resistance at the initial stage of the friction experiment and it was found that the combined surface deformation process is available to fabricate the surface texture for tribological interface.

Microstructure-Based Modeling of Residual Stresses in WC-12Co-Sprayed Coatings

In this study, the residual stresses in a thermal-sprayed tungsten carbide-cobalt coating are numerically investigated after a plasma-spraying process and after a subsequent roller-burnishing process. The results from the simulations are compared to the first experimental results obtained by a classical hole-drilling method. First, effective material parameters are identified by a detailed microstructure FE model based on scanning electron microscope (SEM) images of the coating. Then, two types of simulations are performed with regard to thermally induced residual stresses as well as the rolling process. In the first model, the microstructural details like pores, interface, and surface roughness are modeled in detail based on light microscope (LM) images. In the second model, the coating and substrate are assumed to be ideal homogeneous, and the interface and surface to be as planar. Furthermore, two types of boundary conditions are investigated: (1), the periodic boundary conditions for the left and right faces, and, (2) when these faces are free. It is shown that, for large sample sizes, the results nearly coincide. The simulation results show increasing compressive residual stresses in thickness direction after the rolling process, which is in qualitative agreement with the experiment. A layer of tensile stresses is obtained at the surface in the simulation which could not be captured by the hole-drilling method. Furthermore, an investigation with homogeneous material behavior is performed in 3D.

Investigation of roller burnishing on Zamac5 cast alloy alloyed by copper

PurposeThis paper seeks to investigate the effect of roller burnishing on the surface roughness and hardness of Zn−5% Al alloyed by copper at varied percentages.Design/methodology/approachCopper was added to molten Zn−5%Al cast alloy at different percentages, then the roller burnishing process with different parameters was carried out on the five Zamac5−Cu alloys, however the effect on the surface roughness and hardness was investigated.FindingsIt was found that there is an enhancement on the hardness and the maximum is 18 per cent in Zamac5−10% Cu alloy. The best surfaces result was 0.05 μm that obtained at 0.04 mm rev −1 burnishing feed rate in Zamac5−10% Cu alloy.Originality/valueThe addition of copper is recommended to be added to Zamac5 up to percentage of maximum solubility of copper in Zamac5 alloy.

FINITE ELEMENT APPROACH FOR THE PREDICTION OF RESIDUAL STRESSES IN ALUMINUM WORK PIECES PRODUCED BY ROLLER BURNISHING

Burnishing is a cold rolling process without removal of metal. A set of precision rollers are used to roll on the component surface with adequate pressure. As a result all the premachined peaks gets compressed into valleys thus giving a mirror like surface finish. Surface finish is considered as important factor for the sliding surfaces, in order to have long life. In Burnishing, compressive residual stresses are induced during the process. In the present work, experimental work is carried out to reduce the surface roughness of a specially fabricated aluminum work piece, by roller burnishing process on lathe. High carbon, high chromium roller is used as tool in the roller burnishing process. Various experiments are conducted to investigate the variation of surface roughness (R a) with respect to the variation of burnishing force. Finite element model is developed to compare the experimental results. The results are found to coincide with the values got from the experimental readings, and the variations are less than 10 %.

Fast, curvature-based prediction of rolling forces for porous media based on a series of detailed simulations

Using thermal spraying various surface coatings consisting of different material compositions can be manufactured. Besides different solid phases the resulting coating microstructure often contains a non-negligible amount of pores. In this context a roller burnishing process with a hydrostatic ball-point-tool is examined to compact the thermally sprayed coating, thereby reducing porosity. The rolling process is performed by a robot on free-formed workpieces. A simulation concept for the prediction of forces in a robot-guided roller burnishing process based on a series of detailed ABAQUS simulations is presented. It is shown that, based on these test configurations, the process forces can be calculated much faster and with sufficient precision. Thereby an optimal rolling path, which requires the least amount of normal force to be applied, can be determined efficiently leading to the decision whether a specific robot is equipped to handle the path. Furthermore, the described approach may be used as a pattern to apply similar methods to other engineering problems where accurate simulative solutions exist, but cannot be applied to problems of realistic size due to their expenditure of time.

Thermally Sprayed Coatings as Effective Tool Surfaces in Sheet Metal Forming Applications

Two approaches to produce wear-resistant effective surfaces for deep drawing tools by thermal arc wire spraying of hard materials are presented. Arc wire spraying is a very economic coating technique due to a high deposition rate. The coated surface is very rough compared to that of conventional sheet metal forming tools. In the first approach, the coated surface is smoothed in a subsequent CNC-based incremental roller burnishing process. In this process, the surface asperities on the surface are flattened, and the roughness is significantly reduced. In the second approach, the hard material coatings are not sprayed directly on the tool but on a negative mould. Afterward, the rough “as-sprayed” side of the coating is backfilled with a polymer. The bonded hard metal shell is removed from the negative mould and acts as the surface of the hybrid sheet metal forming tool. Sheet metal forming experiments using tools based on these two approaches demonstrate that they are suitable to form high-strength steels. Owing to a conventional body of steel or cast iron, the first approach is suitable for large batch sizes. The application of the second approach lies within the range of small up to medium batch size productions.

Investigation of roller burnishing process on aluminium 63400 material

Burnishing, a plastic deformation process, is becoming more popular as a super finishing process. The selection of the burnishing parameters to reduce the surface roughness and to increase the surface hardness is especially crucial because of the non-linear characteristic of the burnishing parameter. This paper deals with the results of an experimental program to study the influence of different burnishing conditions on both surface roughness and hardness: namely, burnishing force, feed, step-over and number of passes. Mathematical models are presented for predicting the surface roughness and hardness and of aluminium 63400 caused by roller burnishing. The response surface methodology is used to optimise the burnishing parameters. The optimum surface roughness and its surface hardness are 0.1468 μm and 43.0147 HRC, respectively. The optimum burnishing parameters are: burnishing force 1200 N; feed 200 mm/min; step over 3 mm; and number of pass 2. The impacts ofburnishing parameters on surface characteristics are investigated. Scanning electron microscopy examinations of the burnishing process are also investigated.

An investigation of roller burnishing process on tool steel material using CNC lathe

This paper investigates the surface characteristics of tool steel material in the roller burnishing on CNC lathe. Burnishing is a cold working, surface finishing process in which plastic deformation of surface irregularities takes place by exerting pressure through a hard roller on a surface to generate uniform and work hardened surface. The tool and work piece materials are tungsten carbide (69 HRC) and HCHCr tool steel (35 HRC). The input parameters are burnishing force, speed, feed and the number of passes. The output parameters are surface roughness and surface hardness. The surface roughness has reduced by 127.7% and hardness has improved by 55.5%. The minimum surface roughness obtained in the operating condition of burnishing force of 900 N, feed of 0.1 mm/rev, speed of 600 rpm and fourth number of pass and the value is 0.153 μm. The empirical model is developed for the surface characteristics and validated using Pearson product moment correlation coefficient.

Surface Characteristics Modification of Polyoxymethylene and Polyurethane Using Burnishing

The surface characteristics of polymers play an important role in unlubricated sliding applications that involve a polymer–metal interface because they are relatively softer than most metals. In this article, roller burnishing is introduced as a technique to improve the friction and wear characteristic of polymers in such applications. The polymers used in this study are polyoxymethylene (POM) as a thermoplastic polymer and polyurethane (PUR) as a thermosetting polymer. The combination of moderate values of burnishing force and speed is recommended during burnishing operations. The lowest surface roughness value, R a , achieved for POM is 0.53 μm (32% decrease) and for PUR is 0.57 μm (29% decrease). The tribological behavior of the burnished polymers is found to be predominantly related to their surface quality. The lowest coefficient of friction value achieved in this work for POM is 0.24 (26.8% decrease) for POM and for PUR it is 0.27 (17.7% decrease). The lowest specific wear rate achieved in this work for POM is 0.37 × 10−6 mm3/Nm (27.8% decrease) and for PUR it is 0.47 × 10−6 mm3/Nm (25.2% decrease). These findings show that the roller burnishing process has the capability to improve the surface quality and tribological characteristics of POM and PUR.

Finite Element Analysis of the Roller Burnishing Process for Fatigue Resistance Increase of Engine Components

Highly stressed components of modern aircraft engines, like turbine and compressor blades, have to satisfy stringent requirements regarding durability and reliability. The induction of compressive residual stresses and strain hardening in the surface layer of these components have been proved to be a very promising method to increase their fatigue resistance significantly. Previous research has shown that an improvement of these characteristics can lead to a slow-down of crack propagation or even complete crack closure due to shakedown effects. The required surface layer properties can be achieved by a number of different manufacturing processes, among which roller burnishing is distinguished by the following substantial advantages: high and deep-reaching compressive residual stresses, high strain hardening, and excellent surface quality. The determination of optimal process parameters in order to achieve a defined state of the surface layer still requires an elaborate experimental set-up and subsequent time-consuming and cost-extensive measurements. Therefore, in this article a novel approach for the quantitative prediction of the induced residual stresses by the roller burnishing process is proposed using finite element analysis (FEA). The developed FE models were verified by comparison of the calculated residual stress state with experimental results of roller burnishing tests for different process parameters and materials. The influence of the induced compressive residual stresses and strain hardening on the materials’ fatigue behaviour was examined subsequently using low cycle fatigue (LCF) tests.

Design and fabrication of new type of dynamometer to measure radial component of cutting force and experimental investigation of optimum burnishing force in roller burnishing process

In this work, an attempt has been made to design and fabricate a new type of dynamometer to measure radial component of cutting force using strain gauges. Dynamometer is required to measure the components of cutting force in any metal cutting process. The dynamometer has been calibrated and tested for performance. It is used in roller burnishing experiment on aluminum work piece under various conditions. In roller burnishing, a hard roller is pressed against a rotating cylindrical work piece and parallel to the axis of the work piece on lathe. Optimum values of burnishing force and the corresponding surface roughness value (Ra) are obtained for different lubricant applications in roller burnishing operation. This dynamometer can be manufactured at a low cost and it can be used for tests on lathe in metal cutting laboratories and engineering colleges. Keywords: Dynamometer, strain gauges, roller burnishing, surface roughness value Ra, burnishing force.

Design and Fabrication of New Type of Dynamometer to Measure Radial Component of Cutting force and Experimental Investigation of Optimum Burnishing force in Roller Burnishing Process

In this work, an attempt has been made to design and fabricate a new type of dynamometer to measure radial component of cutting force using strain gauges. Dynamometer is required to measure the components of cutting force in any metal cutting process. The dynamometer has been calibrated and tested for performance. It is used in roller burnishing experiment on aluminum work piece under various conditions. In roller burnishing, a hard roller is pressed against a rotating cylindrical work piece and parallel to the axis of the work piece on lathe. Optimum values of burnishing force and the corresponding surface roughness value (R a ) are obtained for different lubricant applications in roller burnishing operation. This dynamometer can be manufactured at a low cost and it can be used for tests on lathe in metal cutting laboratories and engineering colleges.

Improvement in the Scratch Resistance of Polymers by Roller Burnishing Process

Abstract The ability of engineering polymers to resist scratching action has rapidly become a vital requirement for diverse industrial applications because scratches may greatly reduce the life cycle of the components. Therefore, the present work aims to study the possibility of using roller burnishing process to enhance the scratch resistance of polymers to a single pass scratching action. The effects of burnishing feed rate and roller contact width on the scratch hardness of poly(oxymethylene) and polyurethane were considered. The results revealed that low burnishing feed rate and smaller roller contact width led to an increase in scratch hardness for both polymers. The scratch fractures were also observed using SEM to study the changes in wear modes.

Finishing of Thermally Sprayed Tool Coatings for Sheet Metal Forming Operations by Roller Burnishing

Processing high strength sheet metal materials causes high tribological loads to the surface of forming tools. To increase the wear resistance and therewith the service time of tools, surface coatings containing hard materials are applied by thermal spraying. In the initial “as sprayed” state, the coatings show a rough surface and porous structure, which is not suitable for sheet forming tools. This article describes the finishing of the coatings by subsequent roller burnishing. By the rolling process surface asperities of the coating are flattened and the contact area between the finished surface and the sheet is increased. Furthermore, residual compressive stresses in the surface zone are generated by the rolling process. The tribological properties of the coated and finished surfaces are analyzed in strip drawing tests with uncoated DP600 sheets varying the contact pressure and drawing velocity. It is shown that the process parameters of the roller burnishing process have a strong influence on the surface topology of the friction elements and their tribological properties. The coated and finished friction elements are compared to conventional grinded steel friction elements, made of C60.